Mud Flap

ABSTRACT

The invention comprises a mud flap for deflecting water and roadway debris, which is adapted to be attached to a vehicle behind a wheel of the vehicle. According to the invention, the mud flap comprises a deflecting panel having a longitudinal axis, a front face, a top edge, and a plurality of openings in the deflecting panel. Each of the openings is defined by a pair of horizontal members and a pair of vertical members. Each horizontal member has an upper side and a lower side. Each horizontal member is substantially parallel to the top edge, and each vertical member is substantially perpendicular to the top edge. The upper side and lower side of each horizontal member is preferably substantially planar. Each vertical member is also preferably substantially planar. The sum of the areas of the plurality of openings represents at least about 75% of the total surface area of the front face of the deflecting panel. In a preferred embodiment of the invention, the deflecting panel has a thickness of no more than about ¼ (0.25) inch, the lower side of each horizontal member is disposed rearwardly and downwardly at an angle of about 80° from the longitudinal axis, the total area of the openings is about 85% of the surface area of the front face of the deflecting panel, the opposing vertical members are at least about 10 inches apart, and the lower side of each horizontal member is spaced no more than about ⅛ (0.125) inch away from the lower side of the adjacent horizontal member.

FIELD OF THE INVENTION

[0001] This invention relates generally to mud flaps adapted for use onwheeled vehicles. More particularly, the invention relates to a mud flaphaving a plurality of openings that are adapted to allow air and smallamounts of water and roadway debris to pass therethrough while the flapdeflects larger objects away from following traffic.

BACKGROUND AND DESCRIPTION OF THE PRIOR ART

[0002] Many types of mud flaps have been used for preventing water, mud,rocks and other road debris from being directed rearwardly from a movingwheeled vehicle into the path of following traffic. Typically, mud flapsare substantially rectangular in shape and have a solid deflectingpanel. The top edge of each mud flap is conventionally mounted behind awheel of a vehicle such that the bottom of the mud flap hangs freelynear the roadway surface.

[0003] While conventional solid mud flaps are effective in deflectingwater and roadway debris, they suffer from several disadvantages. First,the solid design of the mud flap prevents any water or other road debrisencountered by the mud flap from passing through the mud flap. As aresult, a large proportion of the water and other road debris isprojected off the sides and the bottom of the mud flap and into the pathof other vehicles. In addition, the solid design of the mud flapprevents air from passing through it, thereby increasing the dragcreated by the mud flap and decreasing fuel economy. Similarly, thesolid mud flap is heavy and, therefore, decreases fuel economy andpayload capacity. Also, the bottom of a solid mud flap may be displacedrearwardly at high rates of speed, thereby reducing the amount of debristhe mud flap deflects. Finally, the solid mud flap increases thetemperature in the area of the tire of the vehicle because air is notpermitted to flow through the mud flap. Increased temperature in thearea of the tire increases the risk of tire failure.

[0004] Several modifications have been made to the conventional solidmud flap to address the disadvantages identified above. For example, mudflaps have been provided with openings to permit some air, water andother debris to pass through the mud flap. Typically, the openings aredefined, at least in part, by rearwardly and downwardly extendinglouvers or flaps. For example, U.S. Pat. No. 3,350,114 of Salisburydescribes a mud flap having a plurality of flexible flaps adapted to beopened by a stream of water and capable of deflecting said streamdownwardly. Absent a stream of water, however, the flexible hinged flapsremain substantially closed over the apertures with which each isassociated. As a result, the mud flap does little to reduce the dragcreated by the mud flap, the weight of the mud flap, the rearwarddisplacement of the bottom of the mud flap at high speeds, or increasedtemperatures in the area of the tire.

[0005] Several patents describe mud flaps having louvers. See, e.g. U.S.Pat. No. 3,088,751; No. 4,660,846; and No. 4,921,276. U.S. Pat. No.5,366,247 of Fischer describes a vehicle splashguard having louversadapted to deflect water and other debris downwardly rather thansidewardly or rearwardly into the path of following traffic. The louversextend generally horizontally across substantially the entire width ofthe splashguard. Similarly, U.S. Pat. No. 5,564,750 of Bajorek et al.describes a mud flap having louvers that extend horizontally acrosssubstantially the entire width of the mud flap. In addition, the mudflap includes a vertical rib member midway between the ends of eachlouver to provide vertical support to the louvers. The louvers of thismud flap, however, do little to reduce the drag forces created by airresistance because the surface area of the openings is small relative tothe surface area of the mud flap panel, and the louvers are angled onlyslightly from the vertical axis. The louvers of this mud flap are alsolikely to break or crack with extended use, thereby increasing the costof the mud flap and the amount of repair and replacement required. Inaddition, the louvers of this mud flap increase the depth of theconventional solid mud flap, which may not be desirable on certain typesof vehicles. Further, the design of this mud flap is complicated, andthe cost of manufacturing is high.

[0006] Other attempts to overcome the disadvantages of the conventionalsolid mud flap have been made. U.S. Pat. No. 5,273,318 of Nakayamadescribes a vehicle mudguard having multiple screens and draining ribs.U.S. Pat. No. 5,582,430 of Bauer et al. describes a spray protectiondevice having an inlet layer and a spacer layer which creates a voidtherebetween. Such screens and layers, however, are typically made frommetal which tends to rust with use and increases the weight of the mudflap. In addition, the complex air flow design of the screens and layerstends to become clogged with use. U.S. Pat. No. 4,964,655 of Tuckerdescribes a heavy duty mud flap made from metal segments connected byrods which contain a plurality of alternating rubber discs and spacers.This mud flap is also heavy and complex, thereby increasing fuelconsumption and manufacturing cost.

[0007] It would be desirable, therefore, if a mud flap could be providedwhich reduces the amount of water and other road debris that isprojected off the sides and bottom of the mud flap. It would also bedesirable if a mud flap could be provided which causes water and otherroad debris passing through its openings to be directed downwardlytoward the roadway. It would also be desirable if a mud flap could beprovided which reduces the weight and drag created by the mud flap,thereby increasing fuel economy, payload capacity, and the amount ofdebris the mud flap deflects. It would also be desirable if a mud flapcould be provided which does not contribute to increasing thetemperature in the area of the tire of a vehicle. It would also bedesirable if a mud flap could be provided which is less complicated andcostly to manufacture and maintain. It would also be desirable if a mudflap could be provided which is not likely to become clogged with useand is suitable for use on substantially all types of vehicles.

ADVANTAGES OF THE INVENTION

[0008] Accordingly, it is an advantage of the invention claimed hereinto provide a mud flap which reduces the amount of water and other roaddebris that is projected off the sides and bottom of the mud flap. Italso an advantage of the invention to provide a mud flap which causeswater and other road debris passing through its openings to be directeddownwardly toward the roadway. It is another advantage of the inventionto provide a mud flap which reduces the weight and drag created by themud flap, thereby increasing fuel economy, payload capacity, and theamount of debris the mud flap deflects. It is still another advantage ofthe invention to provide a mud flap which does not contribute toincreasing the temperature in the area of the tire of a vehicle. It isanother advantage of the invention to provide a mud flap which is lesscomplicated and costly to manufacture and maintain. It is yet anotheradvantage of the invention to provide a mud flap which is not likely tobecome clogged with use and is suitable for use on substantially alltypes of vehicles.

[0009] Additional advantages of this invention will become apparent froman examination of the drawings and the ensuing description.

SUMMARY OF THE INVENTION

[0010] The invention comprises a mud flap for deflecting water androadway debris, which is adapted to be attached to a vehicle behind awheel of the vehicle. According to the invention, the mud flap comprisesa deflecting panel having a longitudinal axis, a front face, a top edge,and a plurality of openings in the deflecting panel. Each of theopenings is defined by a pair of horizontal members and a pair ofvertical members. Each horizontal member has an upper side and a lowerside. Each horizontal member is substantially parallel to the top edge,and each vertical member is substantially perpendicular to the top edge.The upper side and lower side of each horizontal member is preferablysubstantially planar. Each vertical member is also preferablysubstantially planar. The sum of the areas of the plurality of openingsrepresents at least about 75% of the total surface area of the frontface of the deflecting panel. In a preferred embodiment of theinvention, the deflecting panel has a thickness of no more than about ¼(0.25) inch, the lower side of each horizontal member is disposedrearwardly and downwardly at an angle of about 80° from the longitudinalaxis, the total area of the openings is about 85% of the surface area ofthe front face of the deflecting panel, the opposing vertical membersare at least about 10 inches apart, and the lower side of eachhorizontal member is spaced no more than about ⅛ (0.125) inch away fromthe lower side of the adjacent horizontal member.

[0011] In order to facilitate an understanding of the invention, thepreferred embodiments of the invention are illustrated in the drawings,and a detailed description thereof follows. It is not intended, however,that the invention be limited to the particular embodiments described orto use in connection with the apparatus illustrated herein. Variousmodifications and alternative embodiments such as would ordinarily occurto one skilled in the art to which the invention relates are alsocontemplated and included within the scope of the invention describedand claimed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The presently preferred embodiments of the invention areillustrated in the accompanying drawings, in which like referencenumerals represent like parts throughout, and in which:

[0013]FIG. 1 is a front view of a preferred embodiment of the invention.FIG. 1a is an enlarged front view of a portion of the preferredembodiment of the invention illustrated in FIG. 1.

[0014]FIG. 2 is an enlarged side view of a portion of the preferredembodiment of the invention taken along line 2-2 of FIG. 1a.

[0015]FIG. 3 is a front view of an alternative embodiment of theinvention having additional vertical members.

[0016]FIG. 3a is an enlarged front view of a portion of the embodimentof the invention illustrated in FIG. 3.

[0017]FIG. 4 is a side view of the embodiment of a potion of theinvention illustrated in FIG. 3a taken along line 4-4.

[0018]FIG. 5 is a side view of an alternative embodiment of theinvention having rearwardly and downwardly disposed lower sides.

[0019]FIG. 6 is a side view of an alternative embodiment of theinvention having rearwardly and downwardly disposed upper and lowersides.

[0020]FIG. 7 is a side view of an alternative embodiment of theinvention having rearwardly and upwardly disposed upper sides.

[0021]FIG. 8 is a side view of an alternative embodiment of theinvention having rearwardly and upwardly disposed upper and lower sides.

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

[0022] Referring now to the drawings, the apparatus of the invention isillustrated by FIGS. 1 through 8. The preferred embodiment of theinvention is illustrated in FIGS. 1 and 2. As shown in FIGS. 1 and 2,the invention comprises a mud flap for deflecting water and roadwaydebris propelled by the rotating tires of a moving motor vehicle. Themud flap comprises deflecting panel 12 which may be manufactured usingany suitable material conventionally used to make mud flaps such aspolypropylene or some other elastomeric or polymeric material. It isalso contemplated within the scope of the invention that the deflectingpanel may be made from metal. Preferred deflecting panel 12 ispreferably manufactured using current plastic molding technology. In thepreferred embodiment of the invention, the plastomeric material used tomake panel 12 is heated until it becomes a liquid. The liquid may thenbe introduced into a mold where it is allowed to cool and solidify.

[0023] As illustrated in FIG. 1, preferred panel 12 is generallyrectangular in shape, but it is also contemplated within the scope ofthe invention that the panel may be any suitable shape for deflectingwater and roadway debris propelled by the tires of a motor vehicle. In apreferred embodiment of the invention, panel 12 has a thickness of nomore than about ¼ (0.25) inch.

[0024] As best shown in FIG. 2, deflecting panel 12 is adapted to beattached behind a wheel of a vehicle such that it hangs freely from topedge 18 with longitudinal axis 14 substantially perpendicular to theroad surface and front face 16 facing the wheel of the vehicle behindwhich the mud flap is attached. Panel 12 may be attached to the vehicleusing any suitable fasteners conventionally used to attach mud flaps tovehicles such as rivets, threaded fasteners and the like.

[0025] As illustrated in FIG. 1, deflecting panel 12 comprises openings20, each of which is defined by a pair of horizontal members 21 and apair of vertical members 26. Each horizontal member 21 is substantiallyparallel to top edge 18, and each vertical member 26 is substantiallyperpendicular to top edge 18. Openings 20 are substantially rectangularin shape. The surface area of the front face 16 of deflecting panel is12 is the area contained within top edge 18, lower edge 28, left side 30and right side 32. The sum of the areas of openings 20 represents atleast about 75% of the total surface area of front face 16 of deflectingpanel 12. In a preferred embodiment of the invention, the sum of theareas of openings 20 represents about 85% of the total surface area ofthe front face of the deflecting panel. While preferred openings 20 areformed by a mold that is used to define the shape of panel 12, theopenings may be made using any suitable conventional means for makingopenings such as a punch press or the like. It is also contemplated thathorizontal members 21 (including top edge 18) and vertical members 26may be attached together using any suitable conventional adhesive suchas glue, or any suitable conventional fastening device such as threadedfasteners, rivets and the like. It is also contemplated that thehorizontal members (including the top edge) and vertical members may beattached using a plurality of interlocking channels in the members or aplurality of mating slots and tabs in the members.

[0026]FIG. 1a illustrates an enlarged front view of a portion of theembodiment of the invention illustrated in FIG. 1. As shown in FIG. 1a,each horizontal member 21 has upper side 22 and lower side 24. Upperside 22 and lower side 24 are substantially perpendicular to verticalaxis 14, substantially parallel to top edge 18, and preferablysubstantially planar. Openings 20 are defined in part by upper side 22and lower side 24. Openings 20 are substantially rectangular.

[0027]FIG. 2 is an enlarged side view of a portion of deflecting panel12 taken along line 2-2 of FIG. 1a. As best illustrated in FIG. 2, thecross-sectional shape of each horizontal member 21 is substantiallyrectangular. It is also contemplated, however, that the cross-sectionalshape of each horizontal member may be circular, square or any othersuitable shape. In a preferred embodiment of the invention, upper side22 of each horizontal member 21 is spaced no more than about ⅛ (0.125)inch from lower side 24 of the adjacent horizontal member.

[0028]FIG. 3 illustrates an alternative embodiment of the invention. Asshown in FIG. 3, a total of four vertical members 126 are provided ondeflecting panel 112. The additional vertical members are intended toprovide support for horizontal members 121. While FIG. 3 illustratesfour vertical members 126, it is also contemplated within the scope ofthe invention that a total of three, five, or more vertical members 126may be provided to improve the strength and stability of deflectingpanel 112. Openings 120 are defined by a pair of horizontal members 121and a pair of vertical members 126. It is preferred that the verticalmembers are spaced at least about 5 inches apart, and more preferably,at least about 10 inches apart.

[0029]FIG. 3a illustrates an enlarged front view of a portion of theembodiment of the invention illustrated in FIG. 3. As shown in FIG. 3a,each horizontal member 121 has upper side 122 and lower side 124. Upperside 122 and lower side 124 are substantially perpendicular to verticalaxis 114 and vertical member 126, substantially parallel to top edge118, and preferably substantially planar. Openings 120 are defined inpart by upper side 122, lower side 124 and vertical member 126. Openings120 are substantially rectangular. FIG. 3a also shows that verticalmember 126 is substantially parallel to longitudinal axis 114,substantially perpendicular to top edge 118, and substantially planar.

[0030]FIG. 4 illustrates an enlarged side view of a portion ofdeflecting panel 112 taken along line 4-4 of FIG. 3a. As shown in FIG.4, deflecting panel 112 is thicker than the panel illustrated in FIG. 2.While the preferred panel has a thickness of no more than about ¼ (0.25)inch, it is also contemplated that the panel may be thicker than ¼(0.25) inch. It is also contemplated, however, that vertical members 126may be substantially cylindrical or any other suitable configuration. Inthe embodiment shown in FIG. 4, upper sides 122 and lower sides 124 ofhorizontal members 121 are substantially perpendicular to longitudinalaxis 114 and substantially parallel to top edge 118. The cross-sectionalshape of horizontal members 121 is substantially rectangular.

[0031]FIG. 5 illustrates another preferred embodiment of the mud flap.As shown in FIG. 5, the lower side 222 of each horizontal member 221 isdisposed rearwardly and downwardly from front face 216 at an angle ofabout 80° from longitudinal axis 214. The upper side 224 of eachhorizontal member 221 is substantially parallel to top edge 218 andperpendicular to longitudinal axis 214. Each opening 220 is defined bythe upper side of a horizontal member, the lower side of the adjacenthorizontal member, and a pair of opposing vertical members. Top edge 218is substantially perpendicular to longitudinal axis 214. In thisembodiment of the invention, the rearwardly and downwardly disposedlower side 222 deflects water and road debris passing through opening220 downwardly towards the roadway surface and away from followingtraffic.

[0032]FIG. 6 illustrates another preferred embodiment of the mud flap.As shown in FIG. 6, both upper side 322 and lower side 324 of horizontalmembers 321 are disposed rearwardly and downwardly from front face 316at an angle of about 80° from longitudinal axis 314. Openings 320 aredefined by upper side 322 of horizontal member 321, lower side 324 ofthe adjacent horizontal member, and a pair of vertical members. Top edge318 is substantially perpendicular to longitudinal axis 314. In thisembodiment of the invention, the rearwardly and downwardly disposedlower sides of horizontal members 321 deflect water and other debrisdownwardly towards the roadway and away from following traffic. Inaddition, the rearwardly and downwardly disposed upper sides ofhorizontal member 321 improve air flow through the panel.

[0033]FIG. 7 illustrates another preferred embodiment of the mud flap.As shown in FIG. 7, upper side 422 of each horizontal member 421 isdisposed rearwardly and upwardly from front face 416 at an angle ofabout 80° from longitudinal axis 414. Lower side 424 is substantiallyparallel to top edge 418 and perpendicular to longitudinal axis 414.Openings 420 are defined by upper side 422 of each horizontal member421, lower side 424 of the adjacent horizontal member, and a pair ofvertical members. Top edge 418 is substantially perpendicular tolongitudinal axis 414. In this embodiment of the invention, air flowthrough the panel is increased by the rearwardly and upwardly displacedupper sides of the horizontal members.

[0034]FIG. 8 illustrates another preferred embodiment of the mud flap.As shown in FIG. 8, both upper side 522 and lower side 524 of horizontalmembers 521 are rearwardly and upwardly disposed from front face 516 atan angle of about 80° from longitudinal axis 514. Openings 520 aredefined by upper side 522 of horizontal member 521, lower side 524 ofthe adjacent horizontal member, and a pair of vertical members. Top edge518 is substantially perpendicular to longitudinal axis 514. In thisembodiment of the invention, air flow through the panel is increased bythe rearwardly and upwardly displaced upper and lower sides of thehorizontal members.

[0035] In operation, the various embodiments of the deflecting paneldemonstrate the numerous advantages of the invention claimed herein. Therelatively large area of the front face of the deflecting panel that iscomprised of the openings permits a significant amount of air, water anddebris to flow through the panel with minimal rearward displacement ofthe panel. As a result, the panel remains disposed in a positionsubstantially perpendicular to the roadway even when the vehicle istravelling at high speeds. When the panel is disposed in such aposition, it is capable of deflecting a greater amount of water androadway debris away from following traffic. In addition, the increasedamount of air flow through the panel reduces the drag forces created bythe mud flap, thereby increasing fuel efficiency.

[0036] Similarly, the relatively large area of the openings in the panelreduces the overall weight of the panel, thereby increasing fuelefficiency and payload capacity. The large area of the openings in thepanel also permits a substantial amount of water and roadway debris topass through the panel rather than deflect off the sides or bottom ofthe panel and into following traffic. Finally, the large area of theopenings in the panel and the resulting air flow do not allow the mudflap to contribute significantly to an increase in the temperature inthe vicinity of the tire.

[0037] The various embodiments of the openings in the deflecting paneldemonstrate additional advantages of the invention. In certain preferredembodiments of the invention, the horizontal members of the panel areangled rearwardly and downwardly from the tire to increase the amount ofwater and roadway debris deflected downwardly by the panel. As a result,less water and roadway debris will be propelled into following traffic.In other preferred embodiments, the horizontal members of the panel areangle rearwardly and upwardly from the tire to increase the amount ofwater and roadway debris that may flow through the panel rather than offthe sides or the bottom of the panel.

[0038] Finally, the simplicity of the design and method of manufactureof the mud flap demonstrates the advantages of the mud flap claimedherein over existing mud flaps. The minimal thickness of the panel makesit suitable for use on almost all motor vehicles and reduces the problemof clogging in the openings of the panel. The mud flap of the inventionmay be manufactured inexpensively using current molding technology, andit is inexpensive to replace, repair and maintain.

[0039] Although this description contains many specifics, these shouldnot be construed as limiting the scope of the invention but as merelyproviding illustrations of some of the presently preferred embodimentsthereof, as well as the best mode contemplated by the inventor ofcarrying out the invention. The invention, as described herein, issusceptible to various modifications and adaptations, and the same areintended to be comprehended within the meaning and range of equivalentsof the appended claims.

What is claimed is:
 1. A mud flap that is adapted to be attached to avehicle behind a wheel thereof, said mud flap comprising a deflectingpanel having a longitudinal axis, a front face, a top edge, and aplurality of openings therethrough, with each of said openings beingdefined by: (a) a pair of horizontal members each having an upper sideand a lower side, said upper side and said lower side beingsubstantially parallel to the top edge; (b) a pair of opposing verticalmembers, each of which is substantially perpendicular to the top edge;wherein the sum of the areas of the openings represents at least about75% of the total surface area of the front face of the deflecting panel.2. The mud flap of claim 1 wherein the deflecting panel has a thicknessof no more than about ¼ (0.25) inch.
 3. The mud flap of claim 1 whereinthe opposing vertical members are at least about 5 inches apart.
 4. Themud flap of claim 1 wherein the deflecting panel is made from apolymeric material.
 5. The mud flap of claim 1 wherein the lower side ofeach horizontal member is disposed rearwardly and downwardly from thefront face at an angle of about 80° from the longitudinal axis.
 6. Themud flap of claim 1 wherein the lower side and the upper side of eachhorizontal member is disposed rearwardly and downwardly from the frontface at an angle of about 80° from the longitudinal axis.
 7. The mudflap of claim 1 wherein the sum of the areas of the openings representsat least about 85% of the total surface area of the front face of thedeflecting panel.
 8. The mud flap of claim 1 wherein the upper side ofeach horizontal member is spaced no more than about ⅛ (0.125) inch awayfrom the lower side of the adjacent horizontal member.
 9. The mud flapof claim 1 wherein the upper side of each horizontal member is disposedrearwardly and upwardly from the front face at an angle of about 80°from the longitudinal axis.
 10. The mud flap of claim 1 wherein theupper side and the lower side of each horizontal member is disposedrearwardly and upwardly from the front face at an angle of about 80°from the longitudinal axis.
 11. The mud flap of claim 1 wherein theopposing vertical members are no less than about 10 inches apart. 12.The mud flap of claim 1 wherein the upper side is substantially planar.13. The mud flap of claim 1 wherein the lower side is substantiallyplanar.
 14. The mud flap of claim 1 wherein the upper side and the lowerside are substantially planar.
 15. The mud flap of claim 1 wherein thevertical members are substantially planar.